Disassembly

Front Differential Carrier (2 Of 2):

1. Check the runout of the companion flange.
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum runout: 0.10 mm (0.0039 inch).
If the runout is greater than the maximum, replace the companion flange.





2. Check the ring gear backlash.
Using Special Service Tool (SST) 09564-32011 or equivalent, and a dial indicator, measure the ring gear backlash.
Backlash: 0.10-0.18 mm (0.0039-0.0071 inch).
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





3. Measure drive pinion preload.
Using a torque wrench, measure the drive pinion preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.6-1.0 Nm (5.2-8.7 inch lbs.).
4. Check the total preload.
Using a torque wrench and measureing the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting): 0.4-0.6 Nm (3.5-5.2 inch lbs.).
If necessary, disassemble and inspect the differential.
5. w/ Automatic Disconnecting Differential (ADD):
Remove the A.D.D. actuator.
a. Remove the four bolts.





b. Using a hammer handle, remove the actuator.

6. w/ A.D.D.:
Remove the differential tube.





a. Using a (E14) torx socket, remove the four torx bolts.
b. Using a plastic hammer, remove the differential tube.
c. Remove the sleeve.
d. Remove the O-ring from the differential tube.

7. w/o A.D.D.:
a. Remove the four bolts.
b. Using a plastic hammer, remove the differential tube.
8. w/ A.D.D.:
Remove the clutch case.
a. Using a (E14) torx socket, remove the two torx bolts.
b. Using a plastic hammer, remove the clutch case.





9. Remove side oil seal.
Using the SST 09308-00010, remove the side oil seal.





10. w/ A.D.D.:
Using the SST 09350-20015, 09950-0010 (09951-04010, 09952-04010, 09953-04020, 0995-04010, 09955-04010, 09957-04010, 09958-04010), remove the intermediate shaft No.1.

11. Remove the companion flange.
a. Using a chisel and hammer, unstake the nut.





b. Using the SST 09330-00021 to hold the flange, remove the nut.





c. Using the SST 09950-30010 (09951-03010, 09953-03010, 0995-03010, 09955-03030, 0995-03020), remove the companion flange.

12. Remove the oil seal and the oil slinger.





a. Using the SST 09308-10010, remove the oil seal.
b. Remove the oil slinger.

13. Remove the rear bearing and the bearing spacer.





a. Using the SST 09556-22010, remove the rear bearing from the drive pinion.
b. Remove the bearing spacer.
14. Remove the side bearing retainer.
Remove the 10 bolts and tap out the retainer with a plastic hammer.
15. Remove the differential case assembly.
16. Remove the drive pinion from the differential carrier.





17. Remove drive pinion front bearing.
Using the SST 09950-00020 and a press, remove the drive pinion front bearing and washer from the drive pinion.

HINT: If the drive pinion or ring gear are damaged, replace them as a set.

18. Remove drive pinion bearing outer races.





a. Using a brass bar and hammer, remove the front bearing outer race.





b. Using the SST 09502-12010, 09612-65014 (09612-01020, 09612-01050), remove the rear bearing outer race.

19. Remove the side bearing outer races.

HINT:
- Measure the plate washer and note the thickness.
- Tag the bearing outer races to show the location for reassembly.





a. Using the SST 09950-60010 (09951-00540), 09550-70010 (09951-01500) and a press, remove the outer race and plate washer from the bearing retainer.





b. Using the SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) and a press, remove the outer race and plate washer from the differential carrier.

20. Remove the ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver, unstake the five lock plates.
c. Remove the ten bolts and five lock plates.





d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.





21. Remove side bearings.
Using the SST 0995-40010 (09951-4010, 09952-04010, 09953-04020, 09954-04010, 09954-04010, 09955-04060, 09957-4010, 09958-04010), 09950-60010 (09951-00480), remove the two side bearings from the differential case.

HINT: Fix the claws of SST to the notch in the differential case.

22. Disassemble the differential case assembly.





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts:
Pinion shaft.
2 pinion gears.
2 pinion gear thrust washers.
2 side gears.
2 side gear thrust washers.





23. w/ A.D.D.:
using a brass bar and hammer, remove the two bearings.